Floor and wall covering



Jan. 27, 1948. H. R. WOERNER 2,434,974

FLOOR AND WALL COVERING Filed larch 22, 1944 WEAR sunmzz OF SICCATIVE on. cou osmona FOUNDATION IMPREGNATED WITH TAU. UL IMPREGNANT H xR (Quad- 7x Patented Jan. 27, 1948 FLOOR AND WALL COVERING Herbert R. Woerner, Manheim Township, Lancaster County, Pa., assignor to Armstrong Cork Company. Lancaster, Pa., a corporation of Pennsylvania Application March 22, 1944, Serial No. 527,643

16 Claims. 1

This invention relates to floor and wall coverings, and, more particularly, to a floor or wall covering composed of a wear-resistant facing of siccative oil composition disposed on a fibrous foundation or backing carrying a tall oil impregnant capable of imparting strength and waterresistance to the foundation andwhich is substantially non-bleeding or non-staining under normal conditions of manufacture. By the term normal conditions of manufacture" I mean the usual conditions of pressure and heat used in the manufacture of linoleum.

In the floor covering industry in the manufacture of so-called felt base floor coverings and floor coverings comprising a layer of linoleum composition carried by a. felt base backing, customary practice consists in saturating the base or foundation with asphalt to render it waterreslstant and to increase its strength. Asphalt is not particularly desirable for this purpose since in the stoving or curing operation required to cure the facing layer, the asphalt frequently bleeds through into the surface layer. To obviate this undesirable characteristic of the thermoplastic asphalt, common practice is to apply sealing coatings on both sides of the saturated foundation. Such coatings are supposed to seal the asphalt within the foundation. Such practice does not obviate the disadvantages ensuing from the use of asphalt for in many cases the asphalt bleeds through the sealing coatings when heat and pressure are applied in the manufacture of the covering and in the stoving operation, the asphalt may seep through the uncoated edges of the foundation.

In the manufacture of molded inlaid linoleum, for example, granulated linoleum composition is placed on an asphalt saturated felt base or foundation provided with sealing coatings, and disposed under a heated hydraulic press which serves to compact the granular composition and adhere it to the base. The coated carrier is then placed under a second heated hydraulic press, and subjected to heat and pressure to smooth and secure a satisfactory "face" on the covering. Under the conditions of heat and pressure required for the operation, the asphalt saturant is softened and squeezed through the linoleum composition staining the same; in many cases, the asphalt adheres to the press, thus rendering the covering diflicultly removable and staining or discoloring other portions of the backing subsequently disposed in the press.

Asphalt is somewhat brittle and hence coverings in which it is used as a saturant for the base are not as flexible as desired. This characteristic of an asphalt saturant is particularly undesirable in regions where the temperature fluctuates over a wide range and in cold regions for, before the rolled covering can be used, it is necessary that it be heated or warmed to an extent suificient to soften the asphalt to permit the covering to be unrolled. If this is not done the brittle sheet cracks and breaks during the unrolling and installation operations.

A further disadvantage in the use of asphalt as a saturant for the base or foundation of floor or wall covering resides in the fact that an asphalt saturant does not appear to increase the strength of the foundation during the temperatures encountered in the stoving operation; occasionally. when the covering is stoved vertically. difficulty is experienced with the covering tearing and falling in the stoves. This necessarily increases the cost of the covering. In order to render the base water-resistant to a satisfactory degree. a large amount of asphalt need be used per square yard of covering which again increases the cost of the covering and is particularly undesirable in that it greatly increases staining of the facing by bleeding of the asphalt therethrough even though sealing coatings be used.

In certain cases, so-called removable floor coverings are used which are adapted for easy removal after being adhesively secured in place by the rupture of a coating disposed on the rear surface of the covering. I have found, in some cases, that bleeding of the asphalt into the rupturable coating so increases its strength as to remove completely its characteristic of rupturability.

The various characteristics of asphalt saturants for floor and wall coverings as discussed above all lead to the conclusion that it is deflcient in a number of respects as a saturant for this purpose. Its cost is so low, however, that no satisfactory material has been provided in its place and the industry has continued to use asphalt for this purpose while recognizing its disadvantages and expending large sums in research to find a material which would be entirely satisfactory.

The chief object oi my invention is to provide an improved floor or wall covering. An object of my invention is to provide a floor or wall covering having a wear-resistant facing of siccative oil composition disposed on a fibrous base or foundation which is rendered water-resistant and is strengthened by a non-bleeding impregnant 3 including tall oil. A further object is to provide a decorative floor or wall covering having improved characteristics of flexibility, strength, waterresistance, and which can be easily handled in the stoving operations without staining of the decorative, wear-resistant facing. A still further object is to provide a saturated base for floor or wall coverings in which sealing coatings customarily employed to seal the impregnant within the base may be omitted. A still further object is to provide an improved form of molded inlaid linoleum. A still further object is to provide a floor or wall covering composed of molded inlaid linoleum composition on an impregnated felt backing or base. A still further object is to -provide a base or foundation for molded inlaid linoleum which is impregnated with a waterresistant material including tall oil which imparts improved characteristics of flexibility, strength, and water-resistance to the product. A still further object is to provide a floor or wall covering easily removable after being adhesively secured in place. A still further object is to provide a removable floor or wall covering having a rupturabie coating thereon, which coating is not altered to any material extent by the impregnant used to impart the properties of strength and water-resistance to the base or foundation.

This invention relates to a floor or wall covering which comprises a decorative, wear-resistant layer of siccative oil composition, such as linoleum composition or the decorative paint layer customarily employed in felt base floor coverings, secured to and disposed on a felt base or foundation impregnated with a composition including tall oil. The tall oil impregnant imparts strength, flexibility, and water-resistance to the felt base. Tall oil is obtained as a by-product in the manufacture of kraft paper by the sulfate process from pine or fir wood and is supposedly a mixture of fatty acids, rosin acids, and unsaponifiable materials. The respective percentages of such materials in commercial tall oil will vary over a relatively wide range, depending upon its degree of refinement, the methods utilized in its recovery, the type of wood employed in the production of the paper, and other variable factors.

I have found that raw tall 011, that is, tall oil in the form obtainable from sulfate paper manufacturers, or treated tall oil may be used satisfactorily as an impregnant for the felt base or foundation. In some instances, it is desirable to use treated tall oil since it imparts increased water-resistance to the felt foundation. By treated tall oil, 1 mean a material in which the tall oil acids are partially or completely neutralized by reaction with an alkaline salt to form a water-insoluble compound. Such treatment reduces or eliminates attack from alkalies which may come in contact with the impregnated felt base in use. Tall oil which has been oxidized may also be used. The felt base or foundation may be a water-laid felt manufactured in accordance with usual practice. The wear-resistant facing, preferably, is composed of linoleum composition, such as that type commonly known as molded inlaid mix customarily used in the manufacture of molded inlaid linoleum which may be characterized as sandy rather than tacky in composition. It may, of course, be composed of a suitable paint coating as is customary in the manufacture of felt base floor covering or of other types of linoleum composition.

Preferably, a plasticizer or a combination of plasticizers is used with the tall oil and such plasticizer may be paraffin oil, petroiatum, any of the heavier lubricating oils, semi-drying or drying oils, such as soya bean oil, linseed oil, or raw, blown, or hydrogenated caster oil, hydrogenated methyl abietate, and the like. If desired, antioxidants, such as catechol (pyrocatechol), may be incorporated in the compound although any substituted phenolic materials may be used for this purpose as is well-known in the industry. In order to obtain satisfactory impregnation, the tall 011 and plasticizer are dissolved in a solvent therefor, such as carbon spirits, or turpentine, or any of the higher boiling petroleum distillates, such as naphtha, or aromatic distillates, such as toluol or xylol. Preferably, the ingredients and solvents are so proportioned as to leave a 10%- 50% solids content based on the weight of the foundation in the felt foundation disposed throughout the mass thereof and I have found a solids content falling within the range of 20%- 30% provides the most satisfactory amount from the standpoint of commercial manufacturing procedure. It will be understood the solids content of the impregnant may be quite high or low in comparison to the amount of solvent depending upon the manner in which the impregnating operation is conducted. Reinforcing agents may also be incorporated in the impregnant and such reinforcing agents may be animal or vegetable pitch, such as stearine pitch and cottonseed pitch, ethyl cellulose, and semi-drying or drying oils, such as soya bean oil, linseed oil, or raw, blown, or hydrogenated castor oil, if used in sufficiently large proportion. I have found the amount of reinforcing agent may be increased, if desired, to a point where the reinforcing agent acts as a portion of the impregnant rather than merely as a reinforcer therefor. In such case, however, it is necessary that a substantial amount of tall oil be retained in the impregnant in order to obtain the advantages ensuing from its use.

The following examples illustrate compositions satisfactory for use in impregnation of the felt base or foundation:

Example 1 Parts by weight Tall oil (raw) 20 Paraflin oil 1 Carbon spirits '79 Example 2 Parts by weight Tall oil (raw) 7 Stearine pitch 13 Carbon spirits 79 Castor oil 1 Example 3 Parts by weight Talloll (raw) 7 Cottonseed pitch 13 Carbon spirits 80 Example 4 Parts by weight Tall oil (treated) 'l Stearine pitch 13 Carbon spirits 80 Example 5 Parts by weight Tall oil (treated) 20 Paraflin oil 1 Carbon spirits 79 In preparing the floor covering of my invention,

the felt base or foundation is impregnated in any suitable device with an impregnant including tall oil prepared as described above. The tall oil and plasticizer, if a plasticizer be used, are dissolved in the solvent and the impregnant is ready for use. After impregnation of the felt, the felt carrying the impregnant is heated for approximately 16 hours at 195 F. to cure the impregnant and the base is ready for use in the manufacture of floor covering.

In the manufacture of rotary inlaid linoleum, preferably, a thin tacky mix-coat of linoleum composition is placed on the base, and the linoleum composition blocks or tiles laid thereon and adhered thereto. The composition is then stoved to cure the linoleum mix and I have found this treatment also aids to some extent in curing the impregnant of the base if it has not been completely cured previously. In the manufacture of molded inlaid linoleum, preferably, a tacky coatin! of any suitable composition such as a mixture of rosin and boiled oils which fluxes at the temperature of the presses to become tacky may be placed on the felt foundation and the granulated linoleum composition disposed thereon by any suitable means, for example, the devices disclosed in Berger Patents Nos. 2,024,203 and 2,241,051, granted December 17, 1935, and May 6, 1941, respectively. The tacky coating is for the purpose of adhering the ranular composition to the base andseal coatings for the base are not necessary although they may be used if desired. The foundation carrying the granular compositions is then placed under heated hydraulic presses to compact the granular composition and to form a smooth, non-porous surface thereon. The floor covering is then stoved in the manner customary in the industry,

I have found that the use of tall 011 as an impregnant as disclosed above imparts removability characteristics to the floor covering. when forces are exerted on the floor covering to remove it in use, the tall oil impregnated foundation delaminates or splits permitting the floor covering to be easily removed. The portion of the foundation remaining on the base may be easily removed by the application of a suitable solvent to soften the adhesive. The adhesive customarily used in the installation of floor covering is water-soluble and I have found water with a minor portion of wetting agent to aid its penetration through the split portion of the foundation quickly softens the adhesive to permit its ready and easy removal.

I believe this ready removal characteristic is imparted to the felt foundation due to the fact that the foundation is not saturated but is impregnated, using the term "impregnated" to denote that only a sufiicient amount of impregnant is disposed throughout the mass to impart strength and water-resistance thereto but, insufllcient to prevent such delamination when it is desired to remove a covering adhesively secured in place. It does not appear to effect any substantial change in the removability characteristics whether the tall oil impregnant be disposed throughout the mass of the foundation or whether it be present in greater proportion in one section of the floor covering than in another portion thereof. I have determined certain deflnite limits of cohesion within which the feature of ready removability is obtained. Limits of cohesion of 3 to 30 pounds resistance are satisfactory. With greater tensile resistance than 30 pounds the impregnated foundation is too strong to be easily removed; with tensile resistance less than 3 pounds, it is dangerously weak and may be delaminated by severe traffic and excessive wear. To fall satisfactorily within this range, I have found that the impreen nt carried by the foundation should have a solids content within the range of 10 based on the wei of the foundation.

The test hereinafter referred to as the Scott test used to establish the limits of cohesion may be carried on in the following manner:

To one side of a strip of wood 6" long by 2" wide a thin layer of linoleum cement or paste is applied, using a notched doctor blade to distribute the paste or cement evenly over the entire surface. To the paste or cement is immediately ap lied a strip of the covering to be tested 8" x 2" wide, one end of which is placed flush with one end of the strip of wood, the other end extending free beyond the wood strip. After rolling to obtain a satisfactory bond between the wood and the covering, the sample is maintained at normal room temperature for approximately four days to dry the paste or cement. The resistance of the impregnated foundation to tensile forces is determined by placing the sample in 5. Scott tensile strength machine at right angles to the direction of the forces to be exerted. The strength of the forces recorded as the covering is removed from the wood strip measures the resistance of the impregnated foundation to tensile forces.

I have likewise found that the non-bleeding and non-staining characteristics of the impregnant of my invention is of value in connection with other types of removable floor coverings, for example, coverings such as disclosed in Pennell Patent No. 2,274,848, granted March 3, 1942. In the covering provided by the Pennell invention removability is premised upon a rupturable coating. Since my impregnant is non-bleeding, a rupturable coating may be aDDied upon the rear surface of the foundation and such coating is not altered by bleeding of the impregnant thereinto. Of course, in such cases, the impregnant should so strengthen the foundation as to impart thereto greater resistance to tensile forces than the resistance of the coating to such forces.

The attached drawing illustrates a preferred embodiment of my invention, the various elements composing the floor covering being indicated by suitable legends.

My invention presents numerous advantages. A much smaller quantity of impregnant is required to impart required characteristics of strength, flexibility, and water-resistance to the foundation of the covering; staining of the wearing surface of the covering by the saturant during pressing operations and stoving is prevented and my impregnant is more economical since it eliminates the sealing coatings heretofore required and the operations necessary to apply such sealing coatings to the base. Likewise, the large amount of tissue paper required in the rollup operation when asphalt saturated foundations are used is not required with the covering of my invention and this also decreases the cost of manufacture considerably. The covering of my invention does not ball or gum up in advance of the knife during trimming and installation thereof as frequently happens with coverings in which asphalt is used as a saturant and possesses characteristics which enable a satisfactory edge 7 to be obtained. My invention eliminates the enormous investment in special equipment heretofore required to saturate felt bases or foundations with asphalt for the impregnant of my invention may be readily and quickly applied by any type of device. My invention provides a floor covering which can be readily and quickly removed from an installation in which it is adhesively secured in place and which leaves the base of the installation in satisfactory condition to receive a new covering.

While I have described and illustrated a preferred embodiment of my invention, it will be understood my invention is not limited thereto since it may be otherwise embodied within the scope of the following claims.

I claim:

1. As a new article of manufacture, a floor or wall covering comprising a wearing surface of siccative oil composition and a water-resistant, flexible, fibrous foundation containing as its essential non-staining impregnatin ingredients the dried residue of a mixture of tall oil, a plasticizer for the tall oil, and a solvent.

2. As a new article of manufacture. a floor or wall covering comprising a wearing surface of siccative oil composition and a water-resistant, flexible, fibrous foundation containing a substantlally non-staining impregnant including as its essential impregnating ingredients the dried residue of a mixture of tail oil, a plasticizer for the tall oil, and a solvent, the impregnant being disposed throughout the mass of the foundation and having a solids content within the range of to 50% based on the weight of the foundation.

3. As a new article of manufacture, a floor or wall covering according to claim 2 in which the tall oil is oxidized.

4. As a new article of manufacture, a floor or wall covering comprising a wearing surface of siccative oil composition and a water-resistant, flexible, fibrous foundation containing a substantially non-staining impregnant capable of imparting strength and water-resistance thereto, said impregnant including as its essential ingredients the dried residue of a mixture of tall oil, a plasticizer for the tall oil, and a solvent. said impregnant extending throughout the mass of the foundation.

5. As a new article of manufacture, a floor or wall covering according to claim 4 in which the impregnant comprises the dried residue of the following ingredients in approximately the following proportions:

Parts by weight Tall oil n '7 Stearine pitch 13 Castor oil 1 Solvent 79 6. As a new article of manufacture, a floor or wall covering according to claim 4 in which the impregnant comprises the dried residue of the following ingredients in approximately the following proportions:

Parts by weight Tali oil 7 Cottonseed pitch 13 Castor oil 1 Solvent 79 '1. As a new article of manufacture, inlaid linoleum comprising a wearing surface of linoleum composition disosed on a water-resistant.

flexible, fibrous foundation carrying an impregnant capable of imparting strength and water-resistance thereto and which is substantially non-staining under normal conditions of manufacture, said impregnant containing as its essential ingredients the dried residue of a mixture of tall oil and a solvent therefor.

8. As a new article of manufacture, inlaid linoleum according to claim 7 in which the tall oil is oxidized.

9. As a new article of manufacture, inlaid linoleum according to claim 7 in which the impregnant also includes stearine pitch.

10. As a new article of manufacture, inlaid linoleum accordin to claim '7 in which the impregnant also includes cottonseed pitch.

11. As a new article of manufacture, inlaid linoleum accordin to claim 7 in which the impregnant comprises the dried residue of the following ingredients in approximately the following proportions:

Parts by weight Tall oil 7 Stearine pitch l3 Castor oil 1 Solvent 79 12. As a new article of manufacture, molded inlaid linoleum comprising a wearing surface of linoleum composition. a water-resistant, flexible, fibrous foundation, and a tacky coating disposed between the wearing surface and said foundation and adhering the wearing surface to said f oundation, said foundation carrying an impregnant capable of imparting strength and water-resistance thereto and being substantially non-staining under normal conditions of manufacture. said impregnant containing as its essential ingredients the dried residue of a mixture of tall oil, stearine pitch, and a solvent.

13. As a new article of manufacture, a floor or wall covering comprising a wear-resistant facing layer and a water-resistant fibrous foundation containing a substantially non-staining impregnant containing as its essential ingredients the dried residue of a mixture of tall oil, a plasticizer for the tail oil, and a solvent. said foundation being resistant to tensile forces in the range of 3 to 30 pound as determined by the Scott test whereby if the covering is cemented to a base the foundation may be subsequently ruptured to permit removal of the covering from the base.

14. As a new article of manufacture a floor or wall covering comprising a wear-resistant facing layer and a water-resistant fibrous foundation layer containing a substantially non-staining impregnant, the essential ingredients of which consist of a mixture of tall oil and a reinforcing agent for the tall oil, said foundation bein resistant to tensile forces in the range of 3 to 30 pounds as determined by the Scott test, whereby if the covering is cemented to a base, the foundation may be subsequently ruptured internally to permit removal of the covering from the base.

15. As a new article of manufacture, a floor or wall covering comprising a wearing surface applied to a water-resistant flexible fibrous foundation containing a substantially non-stain ing impregnant, the essential ingredients of which consist of a mixture of tall oil and a reinforcing agent for the tall 011.

16. As a new article of manufacture. a floor or wall covering comprising a wearing surface carried upon a water-resistant flexible fibrous foundation layer containing a substantially non- 9 10 staining water-resistant lmpregnant, the es- UNITE sentlal ingredients of which consist of a mixture D STATES PATENTS of tall 011 and reinforcing and plastlcizing agents Number Name Date for the tall 011. 4, 09 Allen Dec. 10, 1940 HERBERT R. WOERNER. 5 44 Allen Feb. 3, 1942 REFERENCES CITED OTHER REFERENCES The following references are of record in the The Paper Industry and Paper World, Nov.

file of this patent: 1942, page 826.

Certificate of Correction Patent No. 2,434,974. January 27, 1948.

HERBERT R. WOERNER It is hereby certified that errors appear in the printed specification of the above numbered patent requiring correction as follows: Column 5, line 39, for the word tail read tall column 7, line 75, for disosed" reed disposed; and that the said Letters Patent should be read with these corrections therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 6th day of April, A. D. 1948.

THOMAS F. MURPHY,

Assistmtt Uommiaaioner of Patents.

9 10 staining water-resistant lmpregnant, the es- UNITE sentlal ingredients of which consist of a mixture D STATES PATENTS of tall 011 and reinforcing and plastlcizing agents Number Name Date for the tall 011. 4, 09 Allen Dec. 10, 1940 HERBERT R. WOERNER. 5 44 Allen Feb. 3, 1942 REFERENCES CITED OTHER REFERENCES The following references are of record in the The Paper Industry and Paper World, Nov.

file of this patent: 1942, page 826.

Certificate of Correction Patent No. 2,434,974. January 27, 1948.

HERBERT R. WOERNER It is hereby certified that errors appear in the printed specification of the above numbered patent requiring correction as follows: Column 5, line 39, for the word tail read tall column 7, line 75, for disosed" reed disposed; and that the said Letters Patent should be read with these corrections therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 6th day of April, A. D. 1948.

THOMAS F. MURPHY,

Assistmtt Uommiaaioner of Patents. 

